Headlight polishing inside and out - Maserati Forum
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post #1 of 20 Old 04-16-2012, 06:16 PM Thread Starter
 
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Headlight polishing inside and out

After all the threads of headlight cleaning/polishing and trying those solutions with no success, I tackled the undocumented:
Cleaned and polished the inside of my Coupe's headlights!

This is a crazy involved job as you need to remove the front bumper cover to get the lights out.

I will document the procedure once I complete the project. But in the meantime, here are some before and after shots.
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post #2 of 20 Old 04-16-2012, 09:36 PM
 
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They look good so far...

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post #3 of 20 Old 04-17-2012, 04:12 AM
 
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Wow what a great job!! I'm having problems with my drivers light where it get cut off and basically I have no distance and I find it extremely unsafe. I hope this clean may help. I just need to first understand why this is happening. It's very annoying

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post #4 of 20 Old 04-17-2012, 07:42 PM Thread Starter
 
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YES! I had to drive around with my brights on to be able to see farther than 10-15ft.

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post #5 of 20 Old 04-17-2012, 09:04 PM
 
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nice job !
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post #6 of 20 Old 04-17-2012, 11:16 PM
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Fantasic. Great DIY info is very valuable to the community!



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post #7 of 20 Old 04-18-2012, 03:50 AM Thread Starter
 
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Headlight lens removal

  1. Use a blunt stiff putty knife with rounded edges
  2. Cut through the black RTV silicone by placing the knife between the lens and black housing
  3. Keeping the knife perpendicular to the lens, slide the knife around the entire seam.
  4. The first pass keep the knife close to the lens, then the second pass keep it close to the housing
  5. There will be about a 1/8" gap between the lens and housing and a strip of RTV that you can begin to remove using a hook shaped tool.
  6. Once the clean out the gap, use the putty knife at an angle to get between the lens the the groove in the housing. Slide the knife around multiple times.
  7. Use the hook tool to clean out the gap. There will be A LOT of RTV in the groove.
  8. Once the gap in the housing is clear of RTV, begin to pry between the lens and the housing using the putty knife.
  9. Pry with the most force in the areas were the housing groove is thicker and backed up my more plastic to avoid braking the groove off the light. WARNING even though I was very careful, I broke the groove on the top side of both lights.
  10. I found that a plastic tire iron for a bicycle worked well to be some more leverage.
  11. Go slow and take your time
  12. Once the lens is removed, separate the painted light shroud by cutting the RTV
  13. Using a plastic glue, fix any cracks in the housing.
  14. On to polishing...
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post #8 of 20 Old 04-18-2012, 04:01 AM Thread Starter
 
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Plastic lens polish

I used:

BlueMagic Headlight Lens Restorer to remove the crud on the inside of the lens.
Meguiar's PlastX for any scratch removal.
Meguiars Headlight Protectant as the final step.

Use a very soft buffing cloth. I also used a foam polishing head for deeper scratches.

I did inside and out.

Be very careful on the inside as it is easy to scratch.
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post #9 of 20 Old 04-18-2012, 04:06 AM Thread Starter
 
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Headlight projector lens and refelctors

Don't forget to clean the projector lens and reflector for the high-beam.

I used a 50/50 mix of distilled water and isopropyl alcohol on a disposable soft foam paint brush. Then a soft polishing cloth to dry.

Note the reflector chrome is very thin, do not rub.
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post #10 of 20 Old 07-22-2012, 09:05 PM
 
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Great work !
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post #11 of 20 Old 05-28-2016, 10:57 PM
 
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Does anyone know if it is possible to buy the clear headlight lens new without buying the entire headlight assembly?
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post #12 of 20 Old 05-29-2016, 08:03 AM
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I doubt it. They are sealed units. You can take them apart with a knife and an oven, but it's not a simple job

C

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post #13 of 20 Old 12-15-2016, 06:56 AM
 
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Sechack I would like to ask you after all these years you have done this great job are the lens still in good condition? I have heard that lens from the inside have a special membrane which shouldnt be destroyed. Have you discovered something like that?
Thank you in advance for your response
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post #14 of 20 Old 12-16-2016, 07:10 AM
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Just to help (maybe) I think the membrane you may be referring to is the coating on the outside which is designed, I understand, to protect the lens from ultra-violet. This itself breaks down in UV light, but can be removed with polishing kits. You can then polish any damage to the plastic. Won't last indefinitely but is certainly sustainable (at least in the UK!)

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post #15 of 20 Old 12-16-2016, 07:15 AM
 
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Thanks a lot Chris :-)
Will last even less here in Greece with the sun.. Basic reason for keeping my lady always down in the garage hehe
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